Professional Documents
Culture Documents
SM 14
SM 14
Workshop Manual
FABIA 2000 ➤
1.4/55 ; 1.4/74 Engine - Fuel Injection
Edition 08.99
Engine code AUA AUB BBY BBZ BKY
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cardiagn.com
The Workshop Manual is intended only for use within the Organisation Škoda. Printed in Czech Republic
It is not permitted to pass it on to other persons. S00.5309.00.20
© ŠKODA AUTO a. s.
FABIA 2000 ➤ 1.4/55 ; 1.4/74 Engine - Fuel Injection
Supple-
Edition Subject Article Number
ment
08.99 Basic Edition S00.5309.00.20
1 07.00 Supplement to Basic Edition S00.5309.01.20
2 03.01 Modifications in Rep. Gr. 01 and 24 S00.5309.02.20
3 06.02 Additions to engines with the engine codes BBY, BBZ S00.5309.03.20
4 06.04 Supplement to engines with the engine codes BKY S00.5309.04.20
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cardiagn.com
Table of Contents
01 – Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 page 1
- Properties of the self-diagnosis ..................................................................... 01-1 page 1
- Technical data of self-diagnosis ..................................................................... 01-1 page 1
- Meaning of the EPC warning lamp (fault lamp for electric accelerator control -K132-) in the
dash panel insert ...................................................................................... 01-1 page 3
- Meaning of the exhaust gas warning light -K83- .................................................. 01-1 page 3
- Connecting up the vehicle system tester -V.A.G 1552- and selecting the control unit for
engine electronics ..................................................................................... 01-1 page 4
- Interrogating and erasing fault memory of engine control unit ................................. 01-1 page 5
- Automatic test sequence ............................................................................. 01-1 page 6
- Performing actuator diagnosis ....................................................................... 01-1 page 7
Self-diagnosis II ......................................................................................... 01-2 page 1
- Readiness code ........................................................................................ 01-2 page 1
- Reading Readiness Code ............................................................................ 01-2 page 1
- Generating readiness code .......................................................................... 01-2 page 2
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Self-diagnosis III ........................................................................................ 01-3 page 1
- Fault table, fault codes 16496...17566 ............................................................. 01-3 page 1
Self-diagnosis IV ....................................................................................... 01-4 page 1
- Fault table, fault codes 17573...18100 ............................................................. 01-4 page 1
Self-diagnosis V ........................................................................................ 01-5 page 1
- Measured value blocks ............................................................................... 01-5 page 1
- Safety measures ....................................................................................... 01-5 page 1
- Reading measured value block ..................................................................... 01-5 page 1
- Measured value blocks, display groups 001...006 - Basic functions .......................... 01-5 page 2
- Measured value blocks, display groups 010...029 - Ignition .................................... 01-5 page 8
Self-diagnosis VI ....................................................................................... 01-6 page 1
- Measured value blocks ............................................................................... 01-6 page 1
- Measured value blocks, display groups 030...049, 099 - Lambda control .................... 01-6 page 1
Self-diagnosis VII ....................................................................................... 01-7 page 1
- Measured value blocks ............................................................................... 01-7 page 1
- Measured value blocks, display groups 050...069 - Speed control ............................ 01-7 page 1
- Measured value blocks, display groups 070...075 - exhaust gas recirculation .............. 01-7 page 5
- Measured value blocks, display group 100 - readiness code .................................. 01-7 page 7
- Measured value blocks, display groups 120...129 - Communication .......................... 01-7 page 8
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- Test lambda probe heating after catalyst .......................................................... 24-4 page 5
- Testing lambda probe and lambda control after catalyst ........................................ 24-4 page 7
- Check lambda probe ageing before catalyst ...................................................... 24-4 page 10
- Testing the engine operating conditions ........................................................... 24-4 page 11
Engine control unit .................................................................................... 24-5 page 1
- Wiring and Component Test with Test Box V.A.G. 1598/31 .................................... 24-5 page 1
- Testing voltage supply for engine control unit .................................................... 24-5 page 1
- Procedure after voltage supply has been interrupted ............................................ 24-5 page 2
- Replacing engine control unit ........................................................................ 24-5 page 3
- Coding engine control unit ........................................................................... 24-5 page 5
- Adjusting the engine control unit to the throttle valve control unit ............................. 24-5 page 6
Testing auxiliary signals ............................................................................. 24-6 page 1
- Testing the speed signal ............................................................................. 24-6 page 1
- Testing signals from/to the air conditioning system .............................................. 24-6 page 2
- Test brake light switch -F- and brake pedal switch -F47- ....................................... 24-6 page 2
- Testing clutch pedal switch -F36- ................................................................... 24-6 page 4
- Activating and deactivating cruise control system (CCS) ....................................... 24-6 page 5
- Testing CCS ............................................................................................ 24-6 page 5
- Testing gear signal .................................................................................... 24-6 page 6
- Test data bus .......................................................................................... 24-6 page 7
28 – Ignition System
Repairing ignition system ............................................................................ 28-1 page 1
- General notes on the ignition system .............................................................. 28-1 page 1
- Removing and installing parts of the ignition system for engines with the engine codes AUA,
AUB ...................................................................................................... 28-1 page 2
- Removing and installing parts of the ignition system for engines with the engine codes BBZ,
BBY, BKY ............................................................................................... 28-1 page 3
- Safety measures ...................................................................................... 28-1 page 3
- Testing hall sender .................................................................................... 28-1 page 4
- Checking the ignition transformer (for engines with the engine codes AUA, AUB) ......... 28-1 page 6
- Check ignition coils with power output stage (engines with engine codes BBY, BKY, BBZ) 28-1 page 8
- Testing knock sensor ................................................................................. 28-1 page 11
- Test combustion misfiring ............................................................................ 28-1 page 13
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01 – Self-diagnosis
01-1 Self-diagnosis I
Note
The self-diagnosis monitors only a part of the injection
and ignition system. The „Current Flow Diagrams, Fault
Finding and Fitting Locations“ binder should always be
used for fault finding.
The engine control unit -J537- is equipped with a fault
memory.
If malfunctions occur in the monitored sensors or compo-
nents, they are stored in the fault memory with indication
of the fault type.
The engine control unit analyses the information and dis-
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tinguishes between the different fault codes ⇒ Fault Ta-
ble ⇒ Chapter 01-3 and ⇒ Chapter 01-4, and stores
these until the fault memory is erased.
Faults that only occur temporarily (sporadically) are out-
put with the suffix „sporadically occurred fault“. On the
display these faults are indicated by the suffix „SP“. Pos-
sible causes of sporadic faults are e.g. a loose contact or
a momentary line interruption. If a sporadic fault no longer
occurs within 40 warming-up phases (engine started at a
temperature of 50°C and switched off at more than 72
°C), the fault is then automatically erased fom the fault
memory.
The stored faults can be read out with the vehicle system
tester -V.A.G 1552- using programme card -6.0- and
higher version or fault reader -V.A.G 1551- using pro-
gramme card -9.0- and higher version or vehicle diagno-
sis, measurement and information system -VAS 5051-.
After the fault or faults have been rectified, it is necessary
to erase the fault memory ⇒ 01-1 page 5 and also to re-
generate the readiness code ⇒ Chapter 01-2.
Note
General information on self-diagnosis is provided in the
operating instructions for the diagnostic devices
-V.A.G 1551-, -V.A.G 1552- or -VAS 5051-.
Equipment
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Exhaust gas recirculation Yes Yes Yes
1) Independent of voltage supply
2) The values are erased if the voltage supply is interrupted.
Note
The preconditions for selecting the desired functions are
given in the following table.
Operation Precondition
Function on the vehicle system tester Engine not run- Engine idling Normal driving
-V.A.G 1552 - ning, ignition
switched on
01 Interrogating control unit version yes yes yes
02 Interrogating fault memory yes1) yes yes
03 Actuator diagnosis yes no no
04 Basic setting2) yes yes yes
05 Erasing fault memory yes yes yes
06 Ending output yes yes yes
07 Coding control unit yes no no
08 Reading measured value block yes yes yes
15 Reading readiness code yes yes yes
1) Only to be carried out with the ignition switched on and if the engine does not start (activate starter for at least 6 seconds).
2) To be carried out after the following operations: replacing of engine control unit, throttle valve control unit, exhaust gas recirculation valve or
engine or disconnecting of battery. The air conditioning and the ACF system are automatically switched off in function 04.
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– Check the dash panel insert and the EPC warning
lamp ⇒ Electrical System; Rep. Gr. 90.
If the EPC warning lamp lights up when the ignition is
switched on:
CHECK
Note
♦ The exhaust warning light may flash or come on as a
steady light. The fault memory must be interrogated
whatever happens ⇒ 01-1 page 5.
♦ The warning light flashes: There is a fault, which is
likely to damage the catalytic converter in this driving CHECK
S01-0091
Functional test:
– Switch on ignition: The exhaust warning light must
light up.
If the gas warning light does not come on when the igni-
tion is switched on:
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– Start engine and run in idle. The gas warning light
must go out after a few seconds.
If the gas warning light does not go out:
Test conditions
• Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
56 and 61 must be o.k. 11 17 23 31
1
• Battery voltage must be at least 11.5 volts.
6 12 18 24 32
2 7 13 19 25 33
3 8 14
• Earth connections between engine (at gearbox hous-
20 26 34
4 9 15 21 27 35
5 10
ing) and body (below battery) o.k. 16 22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
43 53 63
44 54 64
45 55 65
46 56 66
47 57 67
48 58 68
S01-0094
The control unit identification number and the coding are 036906034T MARELLI 4LV 2615 ->
shown on the vehicle system tester display, e.g.: Coding 00031 WSC XXXXX
♦ 036906034T = Part No. of the control unit (for current
control unit version see spare part cata-
logue)89MARELLI 4LV = description of system and
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version
♦
♦ Coding 00031 = coding of control unit with code ver-
sions ⇒ Chapter 24-5
♦ WSC xxxxx = workshop code the -V.A.G 1552-, with
which the last coding was performed (WSC 00000 ap-
pears provided the factory-entered coding has not
been changed)
Note
♦ If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit
⇒ Chapter 24-5.
♦ Incorrect coding of the engine control unit results in:
♦ Handling problems (jerky gear change, load change
jolts etc.)
♦ Increase in fuel consumption
♦ Increase in pollution
♦ Storage of non-existent faults in fault memory
♦ Impossibility of performing certain functions (lambda
control, actuation of activated charcoal filter system,
etc.)
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select address word 01 „Engine electronics“
⇒ 01-1 page 4.
Only if the engine does not start:
– Press key.
Note
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If the ignition was switched off between „Interrogate fault
memory“ and „Erase fault memory“, the fault memory is
not erased.
– Erase the fault memory and then carry out a test drive.
During the test drive the following operating conditions
must be fulfilled:
♦ The coolant temperature should rise beyond 80°C.
♦ Once this temperature is reached, the following oper-
ating states must be reached several times: Idling,
part load, full load, overrun, enrichment.
♦ In case of full load the speed should be increased be-
yond 3500 rpm.
Note
If no fault has been recognized by the self-diagnostic sys-
tem proceed with fault finding as specified in the corre-
sponding fault table in the „Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations“ binder.
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3. Exhaust gas recirculation valve -N18-
Test conditions
• Fuses 1, 3, 7, 9, 10, 14, 16, 17, 24, 25, 28, 35, 48, 52,
11 17 23 31
56 and 61 must be o.k. 1 6 12 18 24 32
2
• Battery voltage must be at least 11.5 volts.
7 13 19 25 33
3 8 14 20 26 34
4 9
• All electrical consumers, e.g. lights and rear window
15 21 27 35
5 10 16 22 28 36
heater, must be switched off. 39 49 59
29 37
30 38
• Throttle valve drive angle senders -G187- and -G188- 40
41
50
51
60
61
o.k 42 52 62
43 53 63
44 54 64
45 55 65
46 56 66
47 57 67
48 58 68
S01-0094
1) Ignore
Note
♦ The actuator diagnosis can only be carried out when
the engine is not running and the ignition is switched
on.
♦ The final control diagnosis is aborted when the engine
is started or when a moment of momentum is detect-
ed.
♦ During the actuator diagnosis the individual actuators
remain activated until the next actuator is selected by
pressing key .
♦ The actuators are tested acoustically or by touch.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ 01-1 page 4.
– Select function 03 „final control diagnosis“.
Vehicle system test Q
Readout on display: 03 - Actuator diagnosis
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Activate throttle valve positioner -V60-:
– Confirm the entry with key Q.
Actuator diagnosis ->
Readout on display: Throttle valve positioner-V60
The throttle valve positioner should open and close the
throttle valve until the next actuator is activated by press-
ing key .
If the throttle valve does not move:
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Actuator diagnosis ->
Readout on display: Fuel pump relay-J17
The fuel pump relay (on the relay plate) must be activated
and deactivated until the next control element is actuated
by pressing the key.
Note
During activation of the fuel pump relay the fuel pump
should also be heard to run at intervals. The door contact
switch must not be actuated during the test.
If the relay does not click:
S01-0092
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– Proceed with the final control diagnosis up to the end.
– Switch off ignition.
– Replace solenoid valve 1 -N80-.
The LED does not flash:
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– Connect test box -V.A.G 1598/31- to wiring loom to
engine control unit ⇒ Chapter 24-5. Do not connect
up the engine control unit.
– Check wiring between the test box and the 6-pin plug
for interruption according to the Current Flow Dia-
gram:
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01-2 Self-diagnosis II
Readiness code
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The readiness code is erased if the fault memory is
erased or if there is an interruption to the voltage supply.
Procedure
– Connect vehicle system tester -V.A.G 1552- and enter
address word 01 „Engine electronics“ ⇒ Chap. 01-1.
– Select function 15 „Readiness code“.
Readiness code
If all diagnoses were performed successfully, the display 00000000 - Test complete
must indicate the following:
– Press key.
– Generate readiness code ⇒ 01-2 page 2.
The readiness code is only generated if all the display positions show 0
1 2 3 4 5 6 7 8 Diagnosis function
0 Catalytic converter
0 Catalytic converter heater (no diagnosis at present/always „0“)
0 Activated charcoal filter system
0 Secondary air injection system (no diagnosis at present/always „0“)
The readiness code is only generated if all the display positions show 0
0 Air conditioning system (no diagnosis at present/always „0“)
0 Lambda probe
0 Lambda probe heater
0 Exhaust gas recirculation
Test conditions
• Vehicle stationary
• On vehicles with an automatic gearbox the selector le-
ver must be in position „P“ or „N“.
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• All electrical consumers such as lights and rear win-
dow heater switched off
• Intake air temperature must be below 60 °C ⇒ display
group 004, display field 4
• Coolant temperature at least 80 °C ⇒ display group
004, display block 3
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
Work step 1: Interrogating fault memory
– Press key.
Note
♦ The readiness code is reset or erased each time the
fault memory is erased.
♦ If the ignition was switched off between „Interrogate
fault memory“ and „Erase fault memory“, the fault
memory is not erased.
– Press key.
Note
The engine must not be readjusted during the work se-
quence.
Work step 3: Activated charcoal filter system diagno-
sis
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display in display field 4 will switch from „Test OFF“ to
„Test ON“.
System in basic setting 70
– Leave engine running at idling speed until „TVV o.k.“ 29% 65% 342mbar TEV O.K.
is read out in display field 4.
If the display does not occur as described:
– Press C key.
Note
The 3rd bit in display field 2 is only set to 1 under partial
load (2500...4000 rpm).
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Note
This diagnosis is only successfully completed if no faults
relating to the lambda probes or the activated charcoal fil-
ter system exist.
Note
It may also take a few minutes until the readout is
changed from „Test ON“ to „Cat B1 o.k.“
If the specified values are not reached:
– Press C key.
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Note
♦ Faults related to the electronic throttle are indicated
on the dash panel insert by the fault lamp for the elec-
tronic accelerator control „EPC warning lamp“).
♦ Faults related to the exhaust are indicated by the „ex-
haust gas warning lamp“ in the dash panel insert.
♦ Explanations regarding fault types (e.g. „open circuit
or short-circuit to earth“) ⇒ Operating instructions for
the vehicle system tester.
♦ If parts are output as faulty: First test all of the cables
and plug connections to these components as well as
the earth cables of the system according to the current
flow diagram. Only if no fault is detected here should
the part be replaced. This applies in particular if faults
are shown as „sporadic“ (SP).
♦ Once the fault has been corrected erase the fault
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memory ⇒ Chapter 01-1 and re-generate the readi-
ness code ⇒ Chapter 01-2.
Printer edition e.g.:
16497 P0113 035
Intake manifold temperature sender -G72-
Signal too high
sporadically occurring fault
Explanations:
16497 = fault code
P0113 = Ignore the SAE code that may appear next to the
fault code.
035 = fault type as digit
Intake manifold temperature sender -G72- = faulty cur-
rent path or fault location
Signal too great = fault type as text
Sporadically occurring fault = fault not always present,
e.g. loose contact
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– Replace engine control unit ⇒ Chapter 24-5
16505 Implausible signal – Test throttle valve control unit ⇒ Chapter 24-2
Throttle valve potentiometer
-G69-1)
16506 Signal too low
Throttle valve potentiometer
-G69-1)
16507 Signal too high
Throttle valve potentiometer
-G69-1)
16514 Electrical fault in the cir- – Testing lambda probe and lambda control upstream
Bank 1 probe 11) cuit of catalytic converter ⇒ Chapter 24-4
– Remove short-circuit or line interruption ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting
Locations.
16517 Signal too low – Testing lambda probe and lambda control upstream
Bank 1 probe 1 elect.1) of catalytic converter ⇒ Chapter 24-4
16518 No activity – Reading measured value block, display group 030
Bank 1 probe 11) ⇒ Chap. 01-6
– Reading measured value block, display group 031
⇒ Chap. 01-6
16519 Heating circuit electrical – Testing lambda probe and lambda control upstream
Bank 1, probe 1 fault of catalytic converter ⇒ Chapter 24-4
16520 Electrical fault in the cir- – Test lambda probe heater downstream of catalytic
Bank 1 probe 21) cuit converter ⇒ Chapter 24-4
16521 Voltage too low – Test lambda control before catalytic converter
Bank 1 probe 21) ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic
converter ⇒ Chapter 24-4
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74 Engine - Mechanics; Rep. Gr. 20
– Test injection valves ⇒ Chapter 24-3
– Testing lambda probe and lambda control upstream
of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control down-
stream of catalytic converter ⇒ Chapter 24-4
16556 System too rich – Test injection valves ⇒ Chapter 24-3
Bank 1, fuel metering system1)
– Testing lambda control before catalyst ⇒ Chapter
24-4
– Reading measured value block, display group 030
⇒ Chap. 01-6
– Test lambda control before catalytic converter
⇒ Chapter 24-4
16585 Electrical fault in the cir- – Test injection valves ⇒ Chapter 24-3
Injector cyl. 1 -N30-2) cuit
16586 Electrical fault in the cir-
Injector cyl. 2 -N31-2) cuit
16587 Electrical fault in the cir-
Injector cyl. 3 -N32-2) cuit
16588 Electrical fault in the cir-
Injector cyl. 4 -N33-2) cuit
16603 Maximum engine speed – Rectify any mechanical engine damage
exceeded
16605 Implausible signal – Read measured value block, display group 062
Angle sender 2 for TV drive ⇒ Chapter 01-7
-G188-1)2)
– Test throttle valve control unit ⇒ Chapter 24-2
16606 Signal too low
Angle sender 2 for TV drive
-G188-1)2)
16607 Signal too high
Angle sender 2 for TV drive
-G188-1)2)
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– Inspecting misfiring detection ⇒ Chapter 28-1
16685 Combustion misfiring – Test injection valves ⇒ Chapter 24-3
Cylinder 11) detected
16686 Combustion misfiring
Cyl. 21) detected
16687 Combustion misfiring
Cyl. 31) detected
16688 Combustion misfiring
Cyl. 41) detected
16705 Implausible signal – Check engine speed sender -G28- ⇒ Chapter 24-3
Engine speed sender -G28-1)
16706 No signal – Remove line interruption or short-circuit ⇒ Current
Engine speed sender -G28-1) Flow Diagrams, Electrical Fault Finding and Fitting
Locations
– Check engine speed sender -G28- ⇒ Chapter 24-3
– Replace engine control unit ⇒ Chapter 24-5
16708 Malfunction – Inspecting knock sensor ⇒ Chapter 28-1
Knock control
– Read measured value block 028 ⇒ Chapter 01-5
16709 Electrical fault in the cir- – Inspecting knock sensor ⇒ Chapter 28-1
Knock sensor 1 -G61- cuit
– Read measured value block 028 ⇒ Chapter 01-5
16710 Implausible signal
Knock sensor 1 -G61-
16711 Signal too low
Knock sensor 1 -G61-
16712 Signal too high
Knock sensor 1 -G61-
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system1)
– Perform basic setting (measured value block 074
16786 Flow rate too great and 075) ⇒ Chapter 01-7
Exhaust gas recirculation
system1)
16787 Malfunction
Exhaust gas recirculation
valve -N18-1)
16788 Control difference
Exhaust gas recirculation
system1)
16791 Signal too low
Potentiometer for exhaust gas
recirculation -G212-1)
16792 Signal too high
Potentiometer for exhaust gas
recirculation -G212-1)
16804 Efficiency too low – Testing lambda probe and lambda control upstream
Bank 1, catalytic converter of catalytic converter ⇒ Chapter 24-4
system1)
– Testing lambda probe and lambda control down-
stream of catalytic converter ⇒ Chapter 24-4
– Testing intake system for tightness ⇒ Chapter 24-3
– Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
Engine - Mechanics; Rep. Gr. 26
– Check catalytic converter ⇒ 1.4/55; 1.4/74 Engine -
Mechanics; Rep. Gr. 26
16825 Flow rate incorrect – Testing solenoid valve 1 for activated charcoal filter
Tank ventilation system1) ⇒ Chapter 01-1, final control diagnosis
– Inspect hoses and connection pipes from fuel tank
up to injection rail ⇒ 1.4/55; 1.4/74 Engine - Me-
chanics; Rep. Gr. 20
– Testing intake system for tightness ⇒ Chapter 24-3
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Pressure sensor for air condi-
tioning system
16917 Signal too high
Pressure sensor for air condi-
tioning system
16946 Voltage too low – testing voltage supply ⇒ Chapter 24-5
Voltage supply
16947 Voltage too high – testing voltage supply ⇒ Chapter 24-5
Voltage supply
16955 Implausible signal – Test brake light switch and brake pedal switch
Brake light switch -F- ⇒ Chapter 24-6
16988 – Replace engine control unit -J537- ⇒ Chapter 24-5
Control unit defective1)
16989
Control unit defective1)
16990
Control unit defective2)
16991 Undervoltage on basic – Adapt engine control unit to throttle valve control unit
Throttle valve control unit settings ⇒ Chapter 24-5
-J338-2)
17022 Implausible signal – Check battery, if necessary charge ⇒ Electrical Sys-
Throttle valve control unit tem; Rep. Gr. 27
-J338-1)2)
– Test throttle valve control unit ⇒ Chapter 24-2
17029 – Testing signals from and to the air conditioning sys-
Air conditioning system inlet/ tem ⇒ Electrical System; Rep. Gr. 90
outlet
17034 Electrical fault in the cir- – Testing signals from and to the warning light -K83-
Exhaust gas warning light cuit ⇒ Electrical System; Rep. Gr. 90
-K83-
17040 Electrical fault in the cir- – Check the fuel consumption signal ⇒ Electrical Sys-
Fuel consumption signal cuit tem; Rep. Gr. 90.
– Test CAN databus ⇒ Chap. 24-6.
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– Replace engine control unit ⇒ Chapter 24-5
17525 Short circuit to earth – Test lambda probe heater downstream of catalytic
Bank 1, probe 2 heating converter ⇒ Chapter 24-4
circuit1)
– Replace engine control unit ⇒ Chapter 24-5
17526 Open circuit – Test injection valves ⇒ Chapter 24-3
Bank 1, probe 2 heating
circuit1)
– Test lambda probe heater downstream of catalytic
converter ⇒ Chapter 24-4
– Replace engine control unit ⇒ Chapter 24-5
17550 Below limit – Adapt engine control unit to throttle valve control unit
Load detection ⇒ Chapter 24-5
– Test throttle valve control unit ⇒ Chapter 24-2
– Test accelerator pedal position sender ⇒ Chapter
24-2
– Test air filter ⇒ Chapter 24-1
– Check engine mechanics
17559 Below leanness limit – Test injection valves ⇒ Chapter 24-3
Bank 1, mixture adaptation
– Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechan-
range 11)
ics; Rep. Gr. 20
17560 Below leanness limit
Bank 2, mixture adaptation – Testing intake system for tightness ⇒ Chapter 24-3
range 21) – Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
Engine - Mechanics; Rep. Gr. 26
– Check exhaust gas recycling system ⇒ 1.4/55; 1.4/
74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for
leaks ⇒ 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20
– Testing lambda probe and lambda control upstream
of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control down-
stream of catalytic converter ⇒ Chapter 24-4
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01-4 Self-diagnosis IV
Fault table, fault codes 17573...18100
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stream of catalytic converter ⇒ Chapter 24-4
17579 Implausible signal – Test throttle valve control unit -J338- ⇒ Chapter 24-
Angle sender 2 for TV drive 2.
-G188-1)2)
– Replace engine control unit ⇒ Chapter 24-5.
17580 Signal too low – Test throttle valve control unit ⇒ Chapter 24-2
Angle sender 2 for TV drive
-G188-1)2)
– Adapt throttle valve control unit ⇒ Chapter 24-5.
17581 Signal too high
Angle sender 2 for TV drive
-G188-1)2)
17582 Deviation of the injec- – Test injection valves ⇒ Chapter 24-3
Bank 1, fuel metering system1) tion periods
– Test fuel pump ⇒ 1.4/55; 1.4/74 Engine - Mechanics;
Rep. Gr. 20
– Testing intake system for tightness ⇒ Chapter 24-3
– Inspect exhaust system for leaks ⇒ 1.4/55; 1.4/74
Engine - Mechanics; Rep. Gr. 26
– Check exhaust gas recirculation system ⇒ 1.4/55;
1.4/74 Engine - Mechanics; Rep. Gr. 26
– Inspect activated charcoal container system for leaks
⇒ 1.4/55; 1.4/74 Engine - Mechanics; Rep. Gr. 20
– Testing lambda probe and lambda control upstream
of catalytic converter ⇒ Chapter 24-4
– Testing lambda probe and lambda control down-
stream of catalytic converter ⇒ Chapter 24-4
17584 Regulating limit – Testing intake system for tightness ⇒ Chapter 24-3
Bank1, lambda correction ac- reached
cording to catalytic converter1)
– Testing lambda probe and lambda control down-
stream of catalytic converter ⇒ Chapter 24-4
– Test lambda probe heater downstream of catalytic
converter ⇒ Chapter 24-4
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Linear lambda probe/refer-
ence voltage1)
17604 Electrical fault – Testing lambda probe heater upstream of catalytic
Bank 1, probe 1, heating converter ⇒ Chapter 24-4
circuit1)
17606 Electrical fault – Test lambda probe heater downstream of catalytic
Bank 1, probe 2, heating converter ⇒ Chapter 24-4
circuit1)
17621 Short circuit to positive – Test injection valves ⇒ Chapter 24-3
Injector cyl. 1 -N30-1)
17622 Short circuit to positive
Injector cyl. 2 -N31-1)
17623 Short circuit to positive
Injector cyl. 3 -N32-1)
17624 Short circuit to positive
Injector cyl. 4 -N33-1)
17645 Open circuit – Test injection valves ⇒ Chapter 24-3
Injector cyl. 1 -N30-1)
17646 Open circuit
Injector cyl. 2 -N31-1)
17647 Open circuit
Injector cyl. 3 -N32-1)
17648 Open circuit
Injector cyl. 4 -N33-1)
17661 Short circuit to earth – Test dash panel insert ⇒ Electrical System;
Fuel consumption signal Rep. Gr. 90
17662 Short circuit to positive
Fuel consumption signal
17743 Regulating limit ex- – Testing intake system for tightness ⇒ Chap. 24-3.
Engine torque monitoring 21)2) ceeded
– Inspect accelerator pedal position sender -G79- and
-G185- ⇒ Chap. 24-2.
– Test throttle valve control unit -J338- ⇒ Chapter 24-
2.
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Ignition outlet 21)
17763 Open circuit3) – Inspect ignition transformer ⇒ Chapter 28-1
Ignition control cyl. 1
– Remove line interruption according to Current Flow
Diagram ⇒ Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
17764 Short circuit to positive3) – Check the ignition coils with power output stage
Ignition control cyl. 1 ⇒ Chapter 28-1.
17765 Short circuit to earth3) – Remove short-circuit according to Current Flow Dia-
Ignition control cyl. 1 gram ⇒ Current Flow Diagrams, Electrical Fault
17766 Open circuit3) Finding and Fitting Locations.
Ignition control cyl. 2
17767 Short circuit to positive3)
Ignition control cyl. 2
17768 Short circuit to earth3)
Ignition control cyl. 2
17769 Open circuit3)
Ignition control cyl. 3
17770 Short circuit to positive3)
Ignition control cyl. 3
17771 Short circuit to earth3)
Ignition control cyl. 3
17772 Open circuit3)
Ignition control cyl. 4
17773 Short circuit to positive3)
Ignition control cyl. 4
17774 Short circuit to earth3)
Ignition control cyl. 4
17793 – Replace engine control unit ⇒ Chapter 24-5
Control unit defective1)
17796
Control unit defective1)2)
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Tank ventilation valve -N80-1) ing to current flow diagram ⇒ Current Flow Dia-
17834 Open circuit grams, Electrical Fault Finding and Fitting Locations
Tank ventilation valve -N80-1)
17847 Incorrect basic setting – Conduct basic setting (measured value block 074)
Potentiometer for exhaust gas ⇒ Chapter 01-7
recirculation -G212-1)
17848 Open circuit – Check the EGR valve ⇒ 1.4/55; 1.4/74 Engine - Me-
Exhaust gas recirculation chanics; Rep. Gr. 26.
valve -N18-1)
– Test exhaust gas recirculation valve ⇒ Chapter 01-1,
17850 Signal too high final control diagnosis.
Potentiometer for exhaust gas
recirculation -G212-1)
17851 Signal too low
Potentiometer for exhaust gas
recirculation -G212-1)
17909 Short circuit to earth – Test fuel pump relay -J17- ⇒ Chapter 01-1, final con-
Fuel pump relay -J17- trol diagnosis
17910 Short circuit to positive – Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
Fuel pump relay -J17- trical Fault Finding and Fitting Locations.
17912 Leak detected – Inspect intake air system for leaks (unmetered air)
Air intake system2) ⇒ Chapter 24-3
– Check exhaust gas recirculation system ⇒ 1.4/55;
1.4/74 Engine - Mechanics; Rep. Gr. 26
– Testing solenoid valve 1 for activated charcoal filter
⇒ Chapter 01-1, final control diagnosis
– Test throttle valve control unit ⇒ Chapter 24-2
17949 Open circuit – Test fuel pump relay ⇒ Current Flow Diagrams, Elec-
Fuel pump relay -J17- trical Fault Finding and Fitting Locations
17950 Implausible signal – Test throttle valve control unit ⇒ Chapter 24-2
Angle sender for TV drive
-G187-2)
– Replace engine control unit ⇒ Chapter 24-5
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Throttle valve control unit setting not fulfilled ⇒ Chapter 24-5
-J338-2)
17967 Incorrect basic setting
Throttle valve control unit
-J338-1)2)
17968 – Repair mechanical damage
Maximum engine speed ex-
ceeded
17972 Undervoltage on basic – Test battery, charge if necessary ⇒ Electrical Sys-
Throttle valve control unit settings tem; Rep. Gr. 27
-J338-2)
– Adapt engine control unit to throttle valve control unit
⇒ Chapter 24-5
17973 Bottom limit not – Check throttle valve for damage or dirt
Throttle valve control unit reached
– Test throttle valve control unit ⇒ Chapter 24-2
17977 Implausible signal – Inspecting cruise control system ⇒ Chap. 24-6
CCS switch -E45-
17978 – Test throttle valve control unit ⇒ Chapter 24-2
Engine control unit blocked1)2)
– Adapt engine control unit to electronic immobiliser
⇒ Electrical System; Rep. Gr. 96.
– Test electronic immobiliser ⇒ Electrical System;
Rep. Gr. 96
17989 Basic setting not per- – Adapt engine control unit to throttle valve control unit
Throttle valve control unit formed ⇒ Chapter 24-5
-J338-
18010 Voltage too low – Perform procedure for voltage interruption ⇒ Chap.
Voltage supply tml. 30 24-5
18019 Short circuit to earth – Inspect databus ⇒ Chapter 24-6
Fault lamp requirement on
– Test exhaust gas warning lamp ⇒ Current Flow Dia-
grams, Electrical Fault Finding and Fitting Locations
18020 Incorrectly coded – Code engine control unit ⇒ Chapter 24-5
Engine control unit
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CU – Testing air conditioning system CU ⇒ Heating and
Air conditioning; Rep. Gr. 87
18044 Missing message from – Inspect databus ⇒ Chapter 24-6
Data BUS drive airbag CU
– Test airbag control unit ⇒ Body Fitting Work;
Rep. Gr. 01
18045 missing message form – Inspect databus ⇒ Chapter 24-6
Data BUS drive electron. CU
– Read out fault memory of electrical system control
unit ⇒ Electrical System; Rep. Gr. 90
18047 Implausible signal – Test accelerator pedal position sender ⇒ Chapter
Sender 1/2 for accelerator 24-2
pedal position -G79- +
-G185-2)
18048 – Inspect engine control unit power supply ⇒ Chapter
Control unit defective1) 24-5
– Replace engine control unit -J537- ⇒ Chapter 24-5
18049 – Read out air conditioning system control unit fault
Read out fault memory of air memory ⇒ Heating, Air conditioning; Rep. Gr. 01
conditioning CU
18056 defective – Inspect databus ⇒ Chapter 24-6
Data BUS drive
– Read out fault memories of all control units (automat-
ic test sequence) ⇒ Chapter 01-1
18057 Missing message from – Inspect databus ⇒ Chapter 24-6
Data BUS drive ABS CU
– Read out fault memories of all control units (automat-
ic test sequence) ⇒ Chapter 01-1
18058 Missing message from – Inspect databus ⇒ Chapter 24-6
Data BUS drive combiinstrument
– Test dash panel insert ⇒ Electrical System;
Rep. Gr. 90
18060 – Self-diagnosis of automatic gearbox CU
Read out fault memory of ⇒ Automatic Gearbox; Rep. Gr. 01
gearbox CU
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tor control -K132-1)
18087 Open circuit
Fault lamp for electr. accelera-
tor control -K132-1)
18097 Implausible message – Test CAN databus cables ⇒ Chap. 24-6
Databus drive from electron. CU
– Inspecting vehicle voltage control unit -J519-
⇒ Electrical System; Rep. Gr. 90.
18099 Open circuit – Inspect databus ⇒ Chapter 24-6
Exhaust gas warning light
-K83-
18100 Short circuit to earth
Exhaust gas warning light
-K83-
18101 Short circuit to positive
Exhaust gas warning light
-K83-
1) If this fault occurs the engine control unit switches on the exhaust gas warning lamp in the dash panel insert. Meaning of the exhaust gas warn-
ing lamp ⇒ Chapter 01-1.
2) If this fault occurs the engine control unit switches on the EPC warning lamp in the dash panel insert. Meaning of the EPC warning lamp
⇒ Chapter 01-1.
3) The faults related to the "ignition control..." regarding the cables between the engine control unit and the power output stage in the ignition coil,
with which the power output stages are actuated by the engine control unit.
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01-5 Self-diagnosis V
Measured value blocks
Safety measures
If test and measuring devices are required during test
drives observe the following:
♦ Always secure the test and measuring devices on the
rear seat and have a second person operate them
there.
If the test and measuring devices are operated from the
passenger seat the passenger could be injured by the re-
lease of the passenger airbag in the event of an accident.
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♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
• The coolant temperature must be at least 80°C ⇒ dis-
play group 004, display field 3.
• All electrical consumers, e.g. lights and rear window
heater, must be switched off (radiator fan must not
run).
• If vehicle is equipped with air conditioning, this must
be switched off.
• On vehicles with an automatic gearbox the selector le-
ver must be in position „P“ or „N“.
• No fault must be present in the fault memory ⇒ Chap.
01-1, interrogate fault memory and erase.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
Read measured value block HELP
– Select function 08 „Read measured value block“ and Enter display group number XXX
the desired display group number.
Note
Read measured value block 4
Display group number 004 is an example to represent the
850 rpm 13.9V 88 C 41 C
sequence.
Note
Proceed according to the following table to switch to an-
other display group:
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Read measured value block 1→ ⇐ Read out on display:
xxxx rpm xx.x °C xx.x % xxxxxxxx
1 2 3 4 ⇐ Display field Specification Analysis:
Setting require- 10111111 ⇒ 01-5 page 2
ments
Lambda control value -15...15 % ⇒ 01-5 page 8
Coolant temperature 80...110 °C ⇒ 01-5 page 3
Engine speed (idling speed) ⇒ 01-5 page 3
Vehicles with engine code AUA 650...850 rpm1)
Vehicles with the engine codes BBY, BKY 660...860 rpm1)
Vehicles with automatic gearbox 580...780 rpm1)
(engine codes AUA, BBY, BKY)
Vehicles with engine code AUB 740...940 rpm1)
Vehicles with engine code BBZ 580...780 rpm1)
1) Current value ⇒ Inspection and Maintenance
Meaning if display = 1
1 2 3 4 5 6 7 8 Meaning
1 Coolant temperature more than 80°C
1 Engine speed less than 2000 rpm
1 Throttle valve closed
1 Lambda control o.k.
1 Operating state - idling
Meaning if display = 1
1 2 3 4 5 6 7 8 Meaning
1 AC compressor disconnected
1 Catalyst hot (over 300 °C)
1 No fault detected in self-diagnosis
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value
– Test throttle valve control unit ⇒ Chapter
24-2
– Performing idling test ⇒ Chap. 24-3
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3 less than ♦ High fuel volume from the activated char- – Testing solenoid valve 1 for activated
2.0 ms coal filter system charcoal filter ⇒ Chapter 01-1, final con-
trol diagnosis
♦ Incorrect injection valve with too great flow – Test injection valves ⇒ Chapter 24-3
rate fitted
– Check part No. of the injection valves
⇒ Spare parts catalogue
greater ♦ Increased engine load due to electric con- – Eliminate load (air conditioning, power
than 4.0 sumers, air conditioning system, engaged steering etc.)
ms driving position or power steering to the stop
♦ Incorrect injection valves with too small flow – Test injection valves ⇒ Chapter 24-3
rate fitted
– Check part No. of the injection valves
⇒ Spare parts catalogue
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Intake manifold -40...120 °C ⇒ 01-5 page 6
temperature
Coolant temperature 80...110 °C ⇒ 01-5 page 6
Supply voltage of the engine control unit 12.5...14.5 V ⇒ 01-5 page 6
Engine speed (idling speed) xxxx rpm1) ⇒ 01-5 page 3
1) Display group 001, display field 1 ⇒ 01-5 page 2.
Note
♦ Re display field 3:
♦ As soon as a fault concerning the coolant temperature
sender -G62- is stored in the fault memory, the engine
control unit uses the intake manifold temperature as a
replacement value to start the engine (starting tem-
perature - replacement value) The temperature then
rises according to a model sequence stored in the
control unit. If the engine is warm after a certain period
a fixed replacement value is displayed. This fixed sub-
stitute value depends on the intake air temperature.
♦ Re display field 4:
♦ The overall temperature range is indicated as nominal
value. The nominal value must be higher than the am-
bient temperature.
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Analysis of display group 004, coolant temperature
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Operating condi- Idling
tion (idling, partial
—
load, enrichment,
trailing throttle)
Driving speed 0 km/h —
Engine load 10...20 % ⇒ 01-5 page 8
Engine speed (idling speed) xxxx rpm1) ⇒ 01-5 page 3
1) Display group 001, display field 1 ⇒ 01-5 page 2.
Note
♦ Re display field 3:
♦ The overall temperature range is indicated as nominal
value. The display value must be higher than the am-
bient temperature.
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Analysis of display group 010, engine load
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Vehicles with engine code AUB 740…6600 rpm —
Vehicles with engine code BBZ 580…6600 rpm —
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xxx — — Text
1 2 3 4 ⇐ Display field Specification Analysis:
Combustion misfir- activated
ing detection
—
(activated, deacti-
vated)
— —
— —
Ignition misfiring cylinder 4 0 ⇒ 01-5 page 10
Analysis of display groups 015 and 016, ignition misfiring cyl. 1 to cyl. 4
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Note
♦ Notes on display groups 3 and 4:
♦ When idling the display value must be 0.0 .
♦ 14 is the largest ignition angle relief.
Note
♦ Notes on display groups 3 and 4:
♦ When idling the display value must be 0.0 .
♦ 14 is the largest ignition angle relief.
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Once cyl- – Check knock sensor plug connection
inder ⇒ Chap. 28-1
clearly
deviates ♦ Engine damage – Test compression ⇒ 1.4/55; 1.4/74 Engine -
from the Mechanical Components; Rep. Gr. 15.
others ♦ Component parts on engine loose – Attach component parts
01-6 Self-diagnosis VI
Measured value blocks
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Status lambda control upstream of catalytic convert- 111 ⇒ 01-6 page 1
er
Note
♦ Re display field 2:
♦ The 3rd display position is only set to 1 in the partial
load region.
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— —
— —
Lambda learned value under partial load -10,0...10,0 % ⇒ 01-6 page 3
(multiplicative) upstream of catalytic con-
verter
Lambda learned value in idling (additive) upstream -10,0...10,0 % ⇒ 01-6 page 3
of catalytic converter
Note
♦ Re display fields 1 and 2:
♦ Low readouts indicate that the engine is running too
rich and the lambda control therefore produces a lean-
er mixture.
♦ High readouts mean that the engine is running too
lean and the lambda control therefore produces a rich-
er mixture.
♦ If the control unit is dead all initialisation values are re-
set.
♦ add = additive - The effect of the fault (e.g. unmetered
air) becomes increasingly less as engine speed rises.
In the case of an additive initialisation value the injec-
tion period is changed by a fixed rate. This rate is in-
dependent of the basic injection period.
♦ mul = multiplicative - The effect of the fault (e.g. faulty
injector) becomes greater as engine speed rises. The
multiplicative learned value is a percentage change in
the injection period. This change is dependent on the
basic injection period.
♦ Initialisation conditions for partial load. Coolant tem-
perature at least 75 C, intake air temperature max. 90
C, driving mode.
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Dis- Readout Possible cause of fault Rectifying fault
play on dis-
field play:
1 and high ♦ High learned values in idling at less high – Testing intake system for tightness
2 lambda learned values in partial load: Unmetered ⇒ Chapter 24-3
initialisa- air in intake manifold region possible
tion val- ♦ Unmetered air between air filter and throttle
ues
– Eliminate cause
valve
♦ Unmetered air at the exhaust manifold gas- – Eliminate cause
ket
♦ Injection valve blocked – Test injection valves ⇒ Chapter 24-3
♦ Fuel pressure too low – Test fuel pressure regulator and holding
pressure ⇒ 1.4/55; 1.4/74 Engine - Me-
chanics; Rep. Gr. 20.
♦ Lambda probe heating defective or lambda – Testing lambda probe heater upstream of
probe dirty catalytic converter ⇒ Chapter 24-4
Note
♦ Re display field 1:
♦ The display must oscillate around 0. If 0 is constantly
displayed, the lambda control has switched from
closed-loop to open-loop control because of a fault in
the lambda control. Interrogate fault memory
⇒ Chapter 01-1.
Note
♦ Re display field 2:
♦ Display 0.450 V equals approx. = 1.0.
♦ Voltage signal „Mixture rich“ (low level of residual ox-
ygen) is below 0.45...V.
♦ Voltage signal „Mixture lean“ (a lot of residual oxygen)
is above 0.45...V.
♦ Through its structure the wide-band lambda probe en-
ables a permanent lambda control due to the signal
routing for deviations as of = 1.
♦ The control is performed dynamic, as the deviation
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from the specification is current and is known as the
concrete value.
Note
♦ regarding display fields 3 and 4:
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♦ The period duration indicates the time between two
voltage jumps (e.g. rich - lean - rich) of the lambda
probe and is thus an indication of the age condition of
the lambda probe. If the given time is exceeded, dis-
play field 4 = B1 S1 N.O.K.
Analysis of display group 036, lambda probe voltage, lambda probe downstream of catalytic con-
verter
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Display group 037 - Lambda control, Lambda
probes downstream of catalytic converter:
• Driving
• Diagnostic device in function 04 - basic setting
Note
♦ Re display field 2:
♦ Voltage signal „Mixture rich (low level of residual oxy-
gen)“ is at approx. 0.7...1.0 V.
♦ Voltage signal „Mixture lean (high level of residual ox-
ygen)“ is at approx. 0.0...0.3 V.
♦ A voltage jump from 0.7...1.0 V to 0.0...0.3 V or vice
versa takes place at the transition from „rich“ to „lean“
and vice versa ( = 1.0).
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rich mixture (fuel surplus or air shortage)
high CO value
B: Lambda probe voltage low
lean mixture (fuel shortage or air surplus)
low CO value
Note
Depending on the operating state of the engine the lamb-
da probe heaters are switched on or off, i.e. the readouts
in display field 2 and 4 may show either „Htg.u(d)C.ON“
or „Htg.u(d)C.OFF“.
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lyst conversion
test
Cat B1 o.k. —
(Test OFF/Test
ON/Cat B1 O.K./
Cat B1 N.O.K.)
Measured value catalytic con- at least 60 %
—
version
Catalytic converter temperature at least 300 °C —
Engine speed 1500…3900 rpm —
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conditioning system OFF
Engine speed (idling speed - specified
value)
Vehicles with engine code 750 rpm
AUA (830 rpm)1)
Vehicles with engine code 840 rpm
AUB (870 rpm)1)
Vehicles with the engine 760 rpm
codes BBY and BKY
Vehicles with engine code 680 rpm
BBZ
Vehicles with automatic gear- 680 rpm
box (800 rpm)1)
Engine speed (idling speed - actual value) xxxx rpm2) ⇒ Chapter 01-5
1) Air conditioning switched on
2) Display group 001, display field 1 ⇒ Chap. 01-5
Note
♦ Re display field 2:
♦ The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is
displayed.
♦ The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely over-
heated.
Note
♦ regarding display fields 3 and 4:
♦ „OFF“ is always displayed on vehicles without air con-
ditioning system.
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Vehicles with engine code AUB 740 ... 6600 rpm —
Vehicles with engine code BBZ 580 ... 6600 rpm —
Note
♦ Re display field 2:
♦ The operating condition is displayed according to the
speed or load. As of increased speed „trailing throttle“
with closed throttle valve is only displayed up to 1450
rpm, after that it returns to idling.
Note
♦ Re display field 3:
♦ The display shows to what extent the idling stabilizer
has „disinitialised“ from the constructively given mean
value. On a new engine the value is in the positive re-
gion because of the higher friction, on a run-in engine
it is in the negative region.
Display field 4 - Operating conditions, meaning of the digits in the 5-digit number block
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Display group 056 - engine speed control, idling
speed stabilisation:
• Engine idling
Note
♦ Re display field 2:
♦ The nominal engine speed specified by the engine
control unit (calculated value internal to control unit) is
displayed.
♦ The nominal engine speed is raised if the battery is
greatly discharged or if the engine is extremely over-
heated.
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Adaption state
(ADP runs, ADP ADP o.k. —
o.k. or ADP n.o.k.)
Initialisation step counter 0...12 —
Throttle valve angle (potentiometer 2 3...97%
—
-G188-)
Throttle valve angle 3...97% —
Potentiometer 1 -G187-
Note
♦ To display group 60:
♦ The adaptation of the throttle valve control unit occurs
with the ignition switched on and accelerator pedal not
depressed.
♦ The engine control unit is adjusted to the throttle valve
control unit by selecting display group under function
04 „Basic setting“. This adjustment must always be
performed if a different throttle valve (or completely
different engine) or a different engine control unit has
been fitted.
♦ If the power supply was interrupted (battery discon-
nected) an adaptation must also be carried out
⇒ Chap. 24-5. Work sequence after a power supply
interruption.
♦ During adaptation the counter in display field 3 counts
up to 12.
♦ The basic setting may only be ended once the counter
in display field 3 has reached step 12.
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Display group 062 - engine speed control, EPC:
• Ignition on, engine stopped
Note
TVV means Tank Vent Valve (activated charcoal filter so-
lenoid valve 1).
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Note
♦ Re display field 1:
♦ During diagnosis the display fluctuates in the region
from 13...25 % to approx. 6 %.
Note
♦ To display group 074:
♦ The adaptation of the exhaust gas recirculation valve
occurs with the ignition on.
♦ The engine control unit is adapted to the exhaust gas
recirculation valve by selecting display group 074 un-
der function 04 „Basic position“. This adaption must
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Engine speed 1800…5600 rpm —
Note
♦ Re display field 3:
♦ An error can already occur under 140 mbar.
Display field 1 - Readiness code - Meaning of the digits in the 8-digit numerical block
The readiness code is only generated if all the display positions show 0
1 2 3 4 5 6 7 8 Diagnosis function
0 Catalytic converter
0 Catalytic converter heating (no diagnosis at present/always „0“)
The readiness code is only generated if all the display positions show 0
0 Activated charcoal filter system (tank ventilation system)
0 Secondary air injection system (not fitted/always „0“)
0 Air conditioning system (currently no diagnosis/always „0“)
0 Lambda probes
0 Lambda probe heater
0 Exhaust gas recirculation
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xxxx rpm xxx Nm xxx Nm Text
1 2 3 4 ⇐ Display field Specification Analysis:
Status active/inactive —
Actual engine load — —
Nominal engine load — —
Engine speed xxxx rpm1) ⇒ Chapter 01-5
1) Display group 001, display field 1 ⇒ Chap. 01-5
Note
♦ To display group 125:
♦ Nominal value = 1; the control units with active data
bus are displayed.
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Installed location overview for engines with the engine codes AUA, AUB
1 - Activated charcoal filter sys-
tem solenoid valve 1 -N80- */** 3
❑ inspecting ⇒ Chap. 01-1
1 6
2 - 3-pin connector 9
❑ for engine speed sender
-G28- 2
3 - Intake manifold pressure 4 5 7 8
sender -G71- * with intake
manifold temperature sender
-G72- **
4 - Intake manifold
5 - Injector - (N30…N33)- *
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6 - Knock sensor -G61- *
❑ Fitting location: Cylinder-
block intake side
❑ inspect ⇒ Chapter 28-1
7 - Engine control unit *
8 - Throttle valve control unit
-J338- *
9 - Engine speed sender -G28- *
❑ inductive pickup
❑ Fitting location: Cylinder-
block intake side 14
10 - Ignition transformer -N152- * 11
16 13
❑ with identification for ignition
D
leads, do not switch
❑ inspect ⇒ Chapter 28-1 12 10
B
11 - 6-pin connector 15
❑ for wide band lambda probe
with lambda probe heating S24-0333
before catalyst
12 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- * 1.4/55;
1.4/74 Engine - Mechanics; Rep. Gr. 26
13 - Sender for coolant temperature -G62- *
❑ inspect ⇒ Chapter 24-2
14 - Hall sender - G40- *
❑ inspect ⇒ Chapter 28-1
15 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm
❑ Fitting location: in the exhaust manifold
❑ 6-pin connector
16 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm
❑ Fitting location: downstream of catalytic converter
❑ 4-pin connector
Installed location overview for engines with the engine codes BBY, BBZ, BKY
1 - Activated charcoal filter sys-
tem solenoid valve 1 -N80- */**
❑ inspecting ⇒ Chap. 01-1
2 - 3-pin connector
❑ for engine speed sender
-G28-
3 - The vacuum regulating valve
(PCV valve)
❑ for crankcase ventilation
4 - Heating resistor of crankcase
ventilation -N79-
5 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
6 - Intake manifold
7 - Injectors -(N30…N33)- *
8 - Knock sensor -G61- *
❑ Fitting location: Cylinder-
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block intake side
❑ inspect ⇒ Chapter 28-1
9 - Engine control unit *
10 - Throttle valve control unit
-J338- *
11 - Engine speed sender -G28- *
❑ inductive pickup
❑ Fitting location: Cylinder-
block intake side
12 - 6-pin connector
❑ Observe current flow dia-
gram
❑ for wide band lambda probe
with lambda probe heating before catalyst
13 - Exhaust gas recirculation valve -N18- */** with exhaust gas recirculation potentiometer -G212- * 1.4/55;
1.4/74 Engine - Mechanics; Rep. Gr. 26
14 - Sender for coolant temperature -G62- *
❑ inspect ⇒ Chapter 24-2
15 - Hall sender -G40- *
❑ inspect ⇒ Chapter 28-1
16 - Lambda probe 1 downstream of catalytic converter -G39- *, 50 Nm
❑ pay attention to the spare part number
❑ in exhaust manifold - engines BBY, BBZ
❑ exhaust tube front - engine BKY
❑ 6-pin connector - pay attention to different connections for engines with the engine codes BKY EU-4 and EU-
2DDK 05.04 ➤
17 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm
❑ Fitting location: downstream of catalytic converter
❑ 4-pin connector
18 - Ignition coils with a power output stage -N70, N127, N291 und N292-
❑ remove with extractor -T 10094-
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functioning of the electrical components.
♦ Do not use sealants containing silicone. Traces of sil-
icone elements drawn in by the engine are not burnt in
the engine and damage the lambda probes.
♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is pos-
sible that the immobiliser blocks the 4AV control unit.
The fault memory must then be interrogated and if
necessary adapted to the control unit ⇒ Chapter 24-
5.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to inter-
rogate the fault memory after having completed all
inspections and repairs, and if necessary erase
⇒ Chapter 01-1.
♦ Vehicles fitted with airbags are equipped with a crash
fuel shut-off. It is intended to reduce the risk of a vehi-
cle fire after a crash as the fuel pump is disconnected
by the fuel pump relay. This installation also enhances
the starting behaviour of the engine. When opening
the door the fuel pump is activated for 2 seconds in or-
der to build up the pressure in the fuel system.
Safety measures ⇒ 24-1 page 12.
Cleanliless rules ⇒ 24-1 page 13.
Inspect intake air system for leaks (unmetered air)
⇒ Chap. 24-3.
Inspecting engine operating conditions ⇒ Chapter 24-4.
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-J338- 23
❑ Contacts of connector gold- 22 9
plated
10 - Activated charcoal filter sys- 21
tem solenoid valve 1 -N80- */** 20 10
❑ ⇒ 1.4/55; 1.4/74 Engine -
Mechanical Components; 11
Rep. Gr. 20 19
11 - Intake manifold 12
❑ disassembling and assem-
bling ⇒ 24-1 page 6 13
12 - Gasket
❑ replace
18 17 16 15 14 S24-0338
13 - 10 Nm
14 - Connecting tube
❑ to exhaust gas recirculation valve
15 - Lambda probe 2 after catalytic converter -G130- *, 50 Nm
❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
❑ with 4-pin connector
❑ Contacts 3 and 4 gilded
❑ Power supply for lamda probe heating supplied via fuel pump relay -J17-
❑ Testing lambda probe and lambda control downstream of catalytic converter ⇒ Chapter 24-4
❑ Test lambda probe heater downstream of catalytic converter ⇒ Chapter 24-4
❑ Fitting location: downstream of main catalytic converter
16 - Connector for lambda probe downstream of catalytic converter
❑ 4-pin
17 - Lambda probe 1 upstream of catalytic converter -G39-*, 50 Nm
❑ coat only thread with hot bolt paste -G 052 112 A3-; paste must not get into the slot of the probe body
❑ pay attention to the spare part number
❑ with 6-pin connector
❑ contacts gold-plated
❑ Power supply for lamda probe heating supplied via fuel pump relay -J17-
❑ Testing lambda probe and lambda control upstream of catalytic converter ⇒ Chapter 24-4
❑ Testing lambda probe heater upstream of catalytic converter ⇒ Chapter 24-4
❑ Fitting location: Engines BBY, BBZ in the exhaust manifold, engine BKY in the front exhaust pipe
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❑ replace if damaged
27 - 10 Nm
28 - Coolant regulator housing
29 - Fuel-intake hose
❑ secure with spring strap clamps
❑ check for firm seating
❑ from fuel filter ⇒ 1.4/55; 1.4/74 Engine - Mechanical Components; Rep. Gr. 20
30 - Connector
❑ for engine control unit
❑ insert or remove only when the ignition is switched off
31 - Engine control unit*
❑ testing voltage supply ⇒ Chapter 24-5
❑ Procedure to follow after power supply interruption has occurred ⇒ Chapter 24-5
❑ replacing ⇒ Chapter 24-5
❑ coding ⇒ Chapter 24-5
❑ Fitting location ⇒ 24-1 page 1, overview of the engine compartment
32 - Retaining frame
33 - 2 Nm
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❑ replace
8 - Guide plate
❑ pay attention to correct in-
stallation position
❑ replace if damaged
9 - O-ring
❑ replace if damaged
10 - 3 Nm
11 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
❑ Testing intake manifold pres-
sure sender ⇒ Chap. 24-2
❑ Inspecting intake manifold
temperature sender ⇒ Chap. 24-2
12 - Intake manifold
❑ out of plastic
❑ pay attention to the spare part number
❑ removing and installing ⇒ 24-1 page 4
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stallation position
❑ replace if damaged
8 - O-ring
❑ replace if damaged
9 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
❑ Testing intake manifold pres-
sure sender ⇒ Chap. 24-2
❑ Inspecting intake manifold
temperature sender
⇒ Chap. 24-2
10 - 3 Nm
Engines with engine codes BBZ; vehicles mit engines BBY and manual gearbox 09.03 ➤
1 - Intake manifold
❑ out of plastic
❑ pay attention to the spare
part number
❑ removing and installing
⇒ 24-1 page 4
2 - Throttle valve control unit
-J338- *
❑ inspect ⇒ Chapter 24-2
❑ if replaced adapt engine con-
trol unit ⇒ Chapter 24-5
3 - 10 Nm
4 - Gasket ring
❑ replace if damaged
5 - 20 Nm
6 - Gasket ring
❑ replace
7 - Guide plate
❑ pay attention to correct in-
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stallation position
❑ replace if damaged
8 - O-ring
❑ replace if damaged
9 - 3 Nm
10 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
❑ Testing intake manifold pres-
sure sender ⇒ Chap. 24-2
❑ Inspecting intake manifold
temperature sender
⇒ Chap. 24-2
1 - Intake manifold
❑ out of plastic
❑ pay attention to the spare
part number
❑ removing and installing
⇒ 24-1 page 4
2 - Throttle valve control unit
-J338- *
❑ inspect ⇒ Chapter 24-2
❑ if replaced adapt engine con-
trol unit ⇒ Chapter 24-5
❑ if replaced adapt automatic
gearbox control unit ⇒ chap.
24-5
3 - 7 Nm
4 - Gasket
❑ replace if damaged
5 - 20 Nm
6 - Gasket ring
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❑ replace
7 - O-ring
❑ replace if damaged
8 - Intake manifold pressure
sender -G71- * with intake
manifold temperature sender
-G72- **
❑ Testing intake manifold pres-
sure sender ⇒ Chap. 24-2
❑ Inspecting intake manifold
temperature sender
⇒ Chap. 24-2
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5
7
S24-0339
Removing
– Unplug connector -arrows- of the injectors.
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
Installing
S10-0099
– Installation is carried out in the reverse order.
Note
♦ Replace O-rings.
♦ before fitting moisten O-rings lightly with clean engine
oil
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Disassembling and assembling the air filter
1 - Air filter top part
2 - Gasket
❑ replace if damaged 4 5 6 7
3 - Filter insert
4 - Air filter bottom part
5
5 - Rubber holder
6 - 3 Nm 6
7 - Gasket ring
❑ check for firm seating
❑ replace if damaged
8 - Inlet connection with control
flap
❑ Inspecting intake manifold 8
preheating ⇒ Chapter 24-3
3
1
2
S24-0331
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B - from 50...105 °C
Read out examples:
♦ 20 °C is in range A and corresponds to a resistance of
2.3...2.6 kΩ
♦ 80 °C is in range B and corresponds to a resistance of
290...330 Ω
Removing
– Pull off hose -1- (engines 04.02 ➤) and remove en-
gine cover -2- with air filter upwards -arrows-.
Installing
– Installation of the engine cover with air filter occurs in
reverse order.
Safety measures
WARNING!
The fuel system is under pressure! Before opening
the system lay cleaning cloths around the connec-
tion point. Reduce pressure by carefully releasing
the connection point.
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– Unplug the 4-pin connector -arrow- from the ignition
transformer.
For engines with the engine codes BBY, BKY, BBZ
Rules of cleanliness
When working on the fuel supply/fuel injection system,
pay careful attention to the following „5 rules“ for cleanli-
ness.
♦ Thoroughly clean the connection points and their sur-
roundings before releasing.
♦ Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!
♦ Carefully cover or close opened components if the re-
pair is not completed immediately.
♦ Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use
any parts which have been stored unwrapped, e.g. on
a shelf or in a tool box.
♦ When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.
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Note
♦ If the throttle valve control unit is replaced, it is then
essential to adapt this new throttle valve control unit to
the engine control unit ⇒ Chap. 24-5.
♦ On vehicles with an automatic gearbox the gearbox
control unit must also be replaced ⇒ Chap. 24-5.
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♦ Handheld multimeter, e.g. -V.A.G 1526 B-
♦ Measuring tool set e.g. -V.A.G 1594 C-
♦ Current flow diagram
Test condition
• Throttle valve is not damaged or dirty.
Test sequence
– Unplug the 6-pin connector from the throttle valve
control unit.
– Measure resistance of throttle valve drive between
contacts 3 + 5.
Specified value: 3...200 Ω
If the specified value is not reached:
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2 83
3 117
4 84
5 118
6 91
Operation
The two accelerator pedal position senders -G79- and
-G185- are located at the accelerator pedal and pass on
the driver input to the engine control unit completely inde-
pendently of each other (when accelerator is depressed).
Both senders are located in a housing.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and
display group 062.
Reading measured value block 62 ->
– Test the nominal value of sender 1 -G79- at idle stop 2% 2% 14% 14%
in display field 3:
Specified value: 3...100 %
Note
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The engine control unit converts the voltage values of the
throttle valve drive angle sender in percentage (in relation
to 5 Volts) (5 Volts power supply correspond to 100%).
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If the lines are not found to be faulty:
Note
Only use gilded contacts to repair contacts in the plug
connection of the sender.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
display group number 003.
Reading measured value block 3 ->
– Read off intake manifold pressure values indicated in 840/min 365mbar 2
display field 2.
Specified value: 240…420 mbar
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– Replace the intake manifold pressure sender -G71-
with intake manifold temperature sender -G72-
⇒ Chap. 24-1.
If the display remains at 91 mbar:
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If the lines are not found to be faulty:
Note
Only use gilded contacts to repair contacts in the plug
connection of the sender.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and
display group 004.
Reading measured value block 4 ->
– Read off intake manifold temperature value in display 840 rpm 13.6V 91 C 62 C
field 4.
1) If a temperature is displayed that is below the ambient temperature of the sender, check the sender wires for transition impedances. Make sure
that the sender heats up or is heated by radiant heat.
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♦ For a temperature of 20 °C the specification is
2.3...2.6 kΩ
♦ For a temperature of 80 °C the specification is
290...330 Ω
If the specified value is not reached:
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
display group 001. Reading measured value block 1 ->
840/min 88 C 4.0% 00111111
– Read off coolant temperatur value indicated in display
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field 2.
Specified value: Coolant temperature
If implausible value appears in the display:
S24-0349
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Test condition
• Battery voltage at least 11.5 V.
Test sequence
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– Disconnect the 3-pin plug connection from the engine V
speed sender -G28- ⇒ Chap. 24-1.
– Connect the multimeter for voltage measurement to
contact 1 (positive) and 3 (earth) of the plug for engine
speed sender.
– Switch on ignition.
Specified value: min. 4.5 V
Test control
11 17 23
Special tools, test and measuring equipment and 1 6 12 18
31
24 32
auxiliary items required 2 7 13 19 25 33
3 8 14 20 26 34
♦ Test box -V.A.G 1598/31- 4
5
9 15 21 27 35
10 16 22 28 36
♦ Handheld multimeter, e.g. -V.A.G 1715- 39 49 59
29 37
30 38
♦ Diode test lamp e.g. -V.A.G 1527- 40 50 60
41 51 61
♦ Measuring tool set e.g. -V.A.G 1594 C- 42 52 62
43
♦ Current flow diagram 53 63
44 54 64
♦ Extractor -T 10094- 45 55 65
46 56 66
47 57 67
Test conditions 48 58 68
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S01-0094
• Fuse 35 must be OK
• Earth connections between the engine (on gearbox
housing) and body (under battery) are o.k.
• Battery voltage at least 11.5 V.
• Engine speed sender o.k.; check ⇒ 24-3 page 1.
• Check that the Hall sender is o.k. ⇒ Chapter 28-1.
• Fuel pump relay OK
Test sequence
– Pull off hose -1- (engines 04.02 ➤) and remove en-
gine cover -2- with air filter upwards -arrows-.
Engines with the engine codes AUA, AUB
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LED must flash.
1
– Repeat test on the plug connections for the injection
valves on cylinder 2 to 4.
– Switch off ignition.
If the LED does not light up on any cylinder:
2 S24-0344
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tion on the injection valves for interruption of each oth-
er.
Line resistance: max. 1.5 Ω
Test sequence
– Check resistance of the individual injection valves.
Specification at 20 °C: 14,0...17,0 Ω
If the engine is warm the resistance increases by approx-
imately 4 to 6 Ω.
If the specified value is not reached:
Test sequence
– Pull off hose -1- (engines 04.02 ➤) and remove en-
gine cover -2- with air filter upwards -arrows-.
– Completely remove the fuel rail with all injection
valves from the intake manifold (the fuel hose remains
connected) ⇒ Chapter 24-1.
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S24-0349
1
S24-0342
Note
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When testing the injection rate also check the jet forma-
tion. The jet must be the same for all injection valves.
Test condition
• Coolant temperature must be at least 80 °C
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⇒ Chapter 01-5 display group 001, display field 2.
Test sequence
Note
♦ Because of the vacuum in the intake system the leak
search spray is sucked in with the unmetered air. The
leak search spray reduces the ignition performance of
the mixture. This results in a drop in engine speed and
a change in the lambda probe voltage.
♦ You must comply with the safety instructions on the
box.
Note
Operation of the thermo-element -2- can easily be tested
by spraying on a cooling spray.
1
Idle testing
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Note 2 S24-0332
Test conditions
• The exhaust system between the cylinder head and
the catalyst must be tight.
• Coolant temperature at least 80 °C ⇒ Chapter 01-5
display group 004, display field 3.
• All electrical components such as lights and rear win-
dow heater must be switched off.
• If vehicle is equipped with air conditioning, this must
be switched off.
• On vehicles with an automatic gearbox the selector le-
ver must be in position „P“ or „N“.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
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Note
The idling speed of the engine is increased if the battery
is heavily discharged or the engine is extremely overheat-
ed.
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Test conditions
11 17 23 31
1
• Fuses No. 3 and 9 must be O.K.
6 12 18 24 32
2 7 13 19 25 33
3 8
• Battery voltage at least 11.5 V.
14 20 26 34
4 9 15 21 27 35
5 10 16
• The fuel pump relay must be OK.
22 28 36
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39 29 37
49 59
30 38
40 50 60
41 51 61
Test sequence 42 52 62
43 53 63
– Connect vehicle system tester -V.A.G 1552-. Start en- 44 54 64
gine and select the address word 01 „Engine electron- 45 55 65
ics“ ⇒ Chapter 01-1. 46 56 66
47 57 67
Engine idling. 48 58 68
S01-0094
– Select function 08 „Read measured value block“ and
display group 041.
Reading measured value block 41 ->
– Check status of the lambda probe heater in display Ht. before c. ON 15 Ohm Ht. after c. ON
field 2.
Specified value: „Ht. before c. ON“.
Note
Depending on the operating state of the engine the lamb-
da probe heaters are switched on or off, i.e. the readouts
in display field 2 may show either „Htg. before C.ON“ or
„Htg. before C.OFF“.
If the specified value is not reached:
Note
Depending on the lambda probe version, the heater can
be connected to contacts 1 + 2 or 3 + 5 of the 6-pin plug
(only on engines with code letters BKY EU-4 and EU-
2DDK 05.04 ➤; the instructions for these engines are list-
ed below in the brackets).
S24-0347
Note
At ambient temperature the resistance of the heating ele-
ment should be approx. 1...5 . The resistance increases
considerably even if the temperature rises only slightly.
If there is an interruption in the lambda probe heating:
S24-0346
2 4 6
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serve display group 041, display field 2.
Display: „Ht. before c. ON.“
Specified value: 11.0...14.5 V
or
Display: „Ht. bf. c. ON“/„Ht. bf. c. OFF“ (alternately)
Specified value: fluctuating between 0...14.5 V
Test conditions
• Coolant temperature at least 80 °C ⇒ display group
004, display block 3.
• The exhaust system must be tight between the cata-
lyst and the cylinder head.
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– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
display group number 030.
– Check status of the lambda control before catalyst
(display field 1):
Reading measured value block 30 ->
Specified value: 111 111 110
Note
The first digit of the 3-digit numerical block (heating) fluc-
tuates between 0 and 1.
If the specified value is not reached:
– Press key.
– Select function 08 „Read measured value block“ and
display group 033.
Reading measured value block 33 ->
– Observe lambda control in display field 1. The readout 2.0% 0.462 V
must fluctuate in the region from -10.0...10.0 %.
– Read off voltage in display block 2. The voltage must
oscillate at least 20 times per minute in the region be-
tween 0 to 1.0 V.
If the display in display field 2 remains constantly on one
value:
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Display Cause Continue test
between Open circuit Check voltage
0.400 .... ⇒ 24-4 page 4
0.500 V
1.105 V Short circuit to posi- Check lambda
tive probe wiring
0.000 V Short circuit to earth ⇒ 24-4 page 4
Note
Depending on the wide-band lambda probe version, it
can be connected to contacts 3+ 4 +5 + 6 or 2 + 1 + 4 +
6 of the 6-pin plug (only on engines with code letters BKY
EU-4 and EU-2DDK 05.04 ➤; the instructions for these
engines are listed below in the brackets).
S24-0347
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– Check wiring between the test box and the 6-pin plug
for interruption according to the Current Flow Dia-
gram.
Test conditions
• Fuses No. 3 and 9 must be O.K. 11 17 23 31
• Battery voltage at least 11.5 V. 1
2
6
7
12
13
18
19
24 32
25 33
• The fuel pump relay must be OK.
3 8 14 20 26 34
4 9 15 21 27 35
5 10 16 22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
Test sequence 43 53 63
44 54 64
– Connect vehicle system tester -V.A.G 1552-. Start en- 45 55 65
46
gine and select the address word 01 „Engine electron- 56 66
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Note
Depending on the operating state of the engine the lamb-
da probe heaters are switched on or off, i.e. the readouts
in display field 4 may show either „Htg. after C.ON“ or
„Htg. after C.OFF“.
If the specified value is not reached:
S24-0348
Note
At ambient temperature the resistance of the heating ele-
ment should be approx. 1...5 . The resistance increases
considerably even if the temperature rises only slightly.
If there is an interruption in the probe heating:
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for interruption:
Test conditions
• The coolant temperature must be at least 80°C, ⇒
display group 004, display field 3.
• The exhaust system between the cylinder head and
the catalyst must be tight.
Note
The 3rd bit in display field 2 is only set to 1 under partial
load (2500...4000 rpm).
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x Lambda control active; specified value: 1/0
1 Lambda probe operational
1 Lambda probe heating on
Note
♦ The lambda control of the lambda probe after catalyst
(B1-S2) is inactive without load.
♦ The first digit of the 3-digit numerical block (heating)
fluctuates between 0 and 1.
If the specified value is not reached:
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Test basic voltage
S24-0348
– Remove the 4-pin plug to the lambda probe -G130-
-arrow-.
– Connect multimeter for voltage measurement to con-
tacts 3 + 4 (plug at engine wiring harness).
– Switch on ignition and measure voltage.
Specified value: 0,40…0.50 V
Test conditions
• The exhaust system between the cylinder head and
the catalyst must be tight.
• The coolant temperature must be at least 80°C, ⇒
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display group 004, display field 3.
Note
This may take a few mlnutes.
Note
Test whether the engine control unit detects the operating
conditions idling, trailing throttle, partial load, enrichment
and full load of the engine.
Test condition
• The coolant temperature must be at least 80°C, ⇒
display group 004, display field 3.
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
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ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
display group number 005.
Reading measured value block 5 ->
– Test whether the control unit recognizes the operating 840/min 20% 0km/h Idling
conditions (display field 4):
♦ Idling
Note
Once engine speed is below 1400 rpm idling is again dis-
played.
♦ Partial load
– Accelerate constantly.
As long as the acceleration is constant the following must
be displayed: Partial load.
♦ Enrichment
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Note
♦ The test box -V.A.G 1598/31- is designed in such a
way that it can be simultaneously connected to the
wiring loom of the engine control unit and to the actual
engine control unit.
♦ The advantage being that the electronic engine con-
trol remains fully operational with the test box con-
nected (e.g. measuring signals while the engine is
running).
♦ Whether the control unit remains connected to the test
box or not, is described in the relevant test proce-
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dures.
♦ The contact numbers of the connector of the control
unit and the socket numbers of the test box are iden-
tical.
DANGER!
To avoid damaging the electronic components,
switch on the relevant measuring range before
connecting the measuring cables and comply with
the test conditions.
V.A.G. 1598/31
S01-0089
Testing voltage supply for engine con-
trol unit
Special tools, test and measuring equipment and
auxiliary items required
♦ Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
♦ Test box -V.A.G 1598/31-
♦ Handheld multimeter, e.g. -V.A.G 1526 B-
♦ Measuring tool set e.g. -V.A.G 1594 C-
♦ Current flow diagram
Test conditions
• Battery voltage at least 11.5 V. 11 17 23 31
• Fuses No. 3, 14, 17, 48, and 56 must be OK. 1
2
6
7
12
13
18
19
24 32
25 33
• AC generator o.k., test: ⇒ Electrical system;
3 8 14 20 26 34
4 9 15 21 27 35
Rep. Gr. 27. 5 10 16 22 28 36
39 29 37
49 59
30 38
40 50 60
41 51 61
42 52 62
Test sequence 43 53 63
44 54 64
– Connect vehicle system tester -V.A.G 1552-. Start en- 45 55 65
46
gine and select the address word 01 „Engine electron- 56 66
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If the specified value is not reached:
Procedure
After the voltage supply has been interrupted, it is neces-
sary to carry out the following steps:
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– Conduct a lengthy test drive until the problems have
been rectified.
During the test drive the following operating conditions
must be fulfilled:
♦ The coolant temperature should rise beyond 80°C.
♦ After reaching the corresponding temperature, the fol-
lowing operating conditions must be reached a
number of times: Idling, part load, full load, overrun.
♦ In case of full load the speed should be increased be-
yond 3500 rpm.
Procedure
– Enter the control unit identification and thus also the
coding of the previous control unit as follows:
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
036906034T MARELLI 4LV 2615 ->
The control unit identification number and the coding are
Coding 00031 WSCXXXXX
shown on the display, e.g.:
S10-0111
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Installation is carried out in the reverse order.
B
– Check current coding and code new control unit
⇒ 24-5 page 5. A
– Adapt engine control unit to control unit for electronic
immobiliser ⇒ Electrical System; Rep. Gr. 96.
– Activate cruise control system function in engine con-
trol unit (on vehicles with CCS the lever for the CCS is
located on the left below the steering wheel) ⇒ Chap.
24-6. S24-0337
– Adapt the new control unit to the throttle valve control
unit ⇒ 24-5 page 6.
– Adapt potentiometer for exhaust gas recirculation.
System in basic setting 74 ->
– Select function 04 „Basic setting“ and display group 0.9V 3.8V 0.968V ADP. O.K.
070 when ignition is switched on.
Specification in display field 4:
ADP runs
ADP O.K.
Note
On vehicles with an automatic gearbox the gearbox con-
trol unit must also be adapted.
Note
♦ A 5-digit code must always be displayed during the
time the control unit identification is shown.
♦ If the code displayed does not match the vehicle, or if
the control unit has been replaced, it is then neces-
sary to code the control unit as follows.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
Code control unit Q
– Select function 07 „coding control unit“. Enter code number XXXXX (0-00127)
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– Enter the relevant code number of the vehicle and
confirm with button Q .
Note
♦ The engine control unit does not use the code entered
and shown in the display until after the ignition has
been switched off. Incorrect coding results in:
♦ Handling problems (jerky gear change, load change
jolts etc.)
♦ Increase in fuel consumption
♦ Increase in pollution
♦ Storage of non-existent faults in fault memory
♦ non-execution of functions (lambda control, activated
charcoal filter system actuation, etc.)
♦ On front-wheel-drive vehicles the Traction Control
System does not operate (TCS warning light on)
♦ Reduction of the gearbox life
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This adaptation teaches the engine control unit the vari-
ous positions of the throttle valve with the ignition on and
the engine stopped. These positions are stored in the en-
gine control unit. The feedback of the throttle valve posi-
tion is provided by the two angle sensors for the throttle
valve drive.
Adaptation must be performed if:
♦ the power supply was interrupted
♦ the throttle valve control unit was removed and in-
stalled
♦ the throttle valve control unit was replaced
♦ if another engine or another throttle valve control unit
was installed
Note
On vehicles with an automatic gearbox the gearbox con-
trol unit must also be adapted.
Test condition
• There must not be any fault present in the fault mem-
ory ⇒ Chap. 01-1, Interrogating fault memory.
• Battery voltage at least 11.5 V.
• Engine not running, ignition switched on.
• Accelerator pedal fully released.
• The throttle valve must be in idling speed position.
Procedure
– Connect vehicle system tester -V.A.G 1552-. Switch
ignition on and select address word 01 „Engine elec-
tronics“ ⇒ Chap. 01-1.
System in basic setting 60 ->
– Select function 04 „Basic setting“ and display group 2% 95% 5 ADP. running
060.
In this state, the throttle valve is moved by a mechanical
spring integrated in the throttle valve control unit, into an
emergency running position. The values generated by
the two angle senders in this emergency position are
stored by the engine control unit.
Subsequently the throttle valve is opened at a given val-
ue. If this value is reached, the throttle valve positioner is
again switched dead. Now the mechanical spring must
close the throttle valve within a given period in the previ-
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ously initialised emergency position (spring test).
The throttle valve is subsequently closed by the throttle
valve positioner: the values sent by the angle sender to
the throttle valve control unit are stored in the engine con-
trol unit.
If during driving the engine control unit switches the throt-
tle valve positioner dead, this is indicated by a fluctuating
increased idling speed. The engine then has a very poor
throttle response.
System in basic setting 60 ->
– Check the specified values for the throttle valve posi- 2% 95% 12 ADP o.k.
tioner control unit in display fields 3 and 4.
Specification in display field 3: 12
Specification in display field 4:
ADP runs
ADP O.K.
If the specified values are reached:
The adaptation was successfully performed.
To store the values:
Note
♦ If the basic setting is aborted by the control unit, this
may be due to the following reasons:
♦ The throttle valve does not reach the mechanical
idling limit due to dirt, e.g. carbon deposits or another
mechanical fault.
♦ The battery voltage is too low.
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Test conditions
• Battery voltage must be at least 11.5 V.
• Speedometer o.k., testing ⇒ Electrical System;
Rep. Gr. 90.
• Fuse 56 o.k.
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Test sequence
Note
♦ The vehicle must be driven in order to test the vehicle
speed signal. The assistance of a second person is
required.
♦ Pay attention to safety precautions for test drives
⇒ Chap. 24-1.
Test conditions
• The air conditioning system must be switched off.
• There must not be any fault in the fault memory, inter-
rogate fault memory ⇒ Chap. 01-1.
Test sequence
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– Connect vehicle system tester -V.A.G 1552 -. Leave
the engine on and select address word 01 „Engine
electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and
display group number 050.
Reading measured value block 50 ->
– Readout on display: 830/min 840/min off off
– Observe display field 2.
Specified value: 840/min
Specifications in display fields 3 and 4: „off“
Test conditions
• Fuses Nos. 2 and 28 O.K.
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Switch
the ignition on and select address word 01 „Engine
Electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and
display group number 066.
Reading measured value block 66 ->
– Check the display value in display field 2. 0 km/h 0000 0 km/h 0000
Specified value: „x x 0 0“
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If the specified values are reached:
– Test the cable to the sender for open circuit and for
short circuit to battery positive or earth ⇒ Current
Flow Diagrams, Electrical Fault Finding and Fitting Lo-
cations.
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47
the ignition on and select address word 01 „Engine 57 67
Test conditions
• There must not be any fault in the fault memory
⇒ Chap. 01-1, Interrogating fault memory.
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Switch
the ignition on and select address word 01 „Engine
Electronics“ ⇒ Chap. 01-1.
036906034F MARELLI 4LV G 2615 ->
Readout on display, e.g.: Coding 00031 WSC XXXXX
If „MARELLI 4LV G“ is displayed, CCS is activated.
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036906034F MARELLI 4LV 2615 ->
Readout on display, e.g.: Coding 00031 WSC XXXXX
If „MARELLI 4LV“ is displayed, CCS is not activated.
Login procedure
– Press and select function 11 „Login procedure“. Enter code number XXXXX
Enter the code number by referring to table below and
confirm entry with Q .
Testing CCS
With the exception of an operating switch the CCS does
not have any components of its own. All functions are
performed by the engine control unit. The minimum vehi-
cle speed for the CCS function is 30 km/h.
Test conditions
• Activate CCS ⇒ 24-6 page 5.
Test sequence
– Connect vehicle system tester -V.A.G 1552 -. Leave
the engine on and select address word 01 „Engine
electronics“ ⇒ Chap. 01-1.
– Select function 08 „Read measured value block“ and
display group number 066.
Reading measured value block 66 ->
– Read off the values in display fields 2 and 4. 0 km/h 0000 0 km/h 0000
Display field 2
Specified value:
1xxx - CCS activated
0xxx - CCS deactivated
Display field 4
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point
Switch -B- to „ON“ 0011
Switch -B- to „RES“ 1011
Switch -A- pressed (switch -B- to „ON“) 0111
1) Not active at present.
A B N23-0199
If the specified values are not reached:
Test condition
• The selector lever of the automatic gearbox must be
in position „P“ or „N“.
• Air conditioning switched off.
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Operation
The engine control unit communicates over a CAN data-
bus with all the control units with databus capability.
The control units with databus capability are linked by two
twisted databus cables (CAN_High and CAN_Low) and
exchange information (messages). Both the engine con-
trol unit and the other CAN data bus control units detect
missing information on the data bus as faults.
Test condition
• A fault is detected by the CAN databus by self-diagno-
sis.
Test sequence
– Switch off the ignition.
– Release the connector of the engine control unit and
unplug it.
– Connect test box -V.A.G 1598/31 - to engine control
unit ⇒ Chap. 24-5. Wiring loom to control unit is not
connected.
– Test the central terminating resistor in the engine con-
trol unit.
– To to this, conduct a resistance measurement be-
tween test box sockets 58 and 60.
Specified value: 60...72 Ω
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28 – Ignition System
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memory ⇒ Chap. 01-1.
♦ Certain inspections may cause the control unit to de-
tect and store a fault. It is therefore necessary to inter-
rogate the fault memory after having completed all
inspections and repairs, and if necessary erase
⇒ Chapter 01-1.
♦ If after fault finding, repair or inspection of compo-
nents the engine starts briefly and then stops, it is pos-
sible that the immobiliser blocks the 4AV control unit.
The fault memory must then be interrogated and if
necessary adapted to the engine control unit
⇒ Chapter 24-5.
Safety measures ⇒ 28-1 page 3.
Setting data, spark plugs ⇒ Inspection and Maintenance.
Removing and installing parts of the ignition system for engines with the engine
codes AUA, AUB
1 - Ignition lead
❑ with shielded plug and spark-
plug
❑ Resistor 4.8...7.2 kΩ
2 - Ignition transformer -N152-
❑ with identification for ignition
leads:
A = Cylinder 1
B = Cylinder 2
C = Cylinder 3
D = Cylinder 4
❑ check ⇒ 28-1 page 6
❑ Fitting location ⇒ Chapter
24-1
3 - Connector
❑ 4-pin
❑ for ignition transformer
-N152-
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4 - 10 Nm
5 - Connector
❑ 2-pin
❑ for knock sensor 1 -G61-
❑ Contacts of connector gold-
plated
6 - Knock sensor 1 -G61- *
❑ check ⇒ 28-1 page 11
❑ Fitting location ⇒ Chapter
24-1
7 - 20 Nm
❑ The tightening torque influ-
ences the knock sensor func-
tion
8 - Connector
❑ 3-pin
❑ for hall sender -G40-
9 - Hall sender -G40- *
❑ check ⇒ 28-1 page 4
❑ Fitting location ⇒ Chapter 24-1
10 - O-ring
❑ replace if damaged
11 - Ignition lead guide
12 - Spark-plug, 30 Nm
❑ use of the spark plug wrench e.g. -3122 B- for removing and installing
❑ type and electrode gap ⇒ Inspection and Maintenance
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ences the knock sensor func-
tion
6 - Connector
❑ 3-pin
❑ for hall sender -G40-
7 - Hall sender -G40- *
❑ check ⇒ 28-1 page 4
❑ Fitting location ⇒ Chapter
24-1
8 - O-ring
❑ replace if damaged
9 - 10 Nm
10 - Spark-plug, 30 Nm
❑ use of the spark plug wrench
e.g. -3122 B- for removing and installing
❑ type and electrode gap ⇒ Inspection and Maintenance
11 - Bracket
❑ Tighten at cylinder head cover to 5 Nm
Safety measures
Observe the following points to prevent injury to persons
and/or damage to the injection and ignition system:
♦ Do not touch or remove ignition leads with the engine
running or at start speed.
♦ Ignition must be switched off before disconnecting
and re-connecting cables of the fuel injection and igni-
tion system as well as of test equipment.
If test and measuring devices are required during test
drives observe the following:
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Testing hall sender
Special tools, test and measuring equipment and
auxiliary items required
♦ Test box -V.A.G 1598/31-
♦ Handheld multimeter, e.g. -V.A.G 1715-
♦ Measuring tool set e.g. -V.A.G 1594 C-
♦ Current flow diagram
Test condition
• Battery voltage at least 11.5 V.
Test sequence
– Pull off hose -1- (engines 04.02 ➤) and remove en-
gine cover -2- with air filter upwards -arrows-.
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Specified value: min. 4.5 V
Test conditions
• Battery voltage at least 11.5 V.
• The hall sender must be OK, test it ⇒ 28-1 page 4.
• The engine speed sender must be O.K., test it
⇒ Chapter 24-3.
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Test sequence
– Unplug the 4-pin connector -arrow- from the ignition
transformer.
Test control
WARNING!
During the following test do not touch neither the
connecting parts of the ignition transformer nor
the auxiliary cables.
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– Connect the diode test lamp to contacts 1 + 4 (ignition
outlet 1) and contacts 3 + 4 (ignition outlet 2) of the re-
moved plug.
– Actuate the starter and check the ignition signal on the
engine control unit. The LED must flash.
– Switch off ignition.
If the LED flashes and there is a voltage existing between
contact 2 and 4:
Checking wires
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is
not connected here.
– Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Dia-
gram.
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– Replace engine control unit ⇒ Chapter 24-5.
Test sequence
Note
Ignition coil and power output stage form a building unit.
Cylinder, which does not operate or misfire, determine as
follows:
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the one of another cylinder.
If the fault on this ignition coil still exists:
Test condition
• The fuses of the ignition system must be in proper or-
der ⇒ Current Flow Diagrams, Fault Finding and Fit-
ting Locations.
Test control
WARNING!
Caution! During the following test do not touch
neither the connecting parts of the ignition coils
nor the auxiliary cables.
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– Connect the diode test lamp V.A.G 1527 with adapter
cables from V.A.G 1594 to contacts 1 + 4 of the re-
moved plug.
– Actuate the starter and check the ignition signal on the
engine control unit.
The LED must light up.
– Check wires.
– Check wiring between the test box and the 4-pin plug
for interruption according to the Current Flow Dia-
gram:
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cylinder: -V.A.G 1598/31-
1 102
2 103
3 94
4 95
Note
♦ The perfect functioning of the knock sensor requires
an exact tightening torque of 20 Nm.
♦ Only use gilded contacts to repair contacts in the plug
connection of the sender.
Test condition
• Faults on the knock sensor detected by self-diagnosis
⇒ Chapter 01-1, interrogate fault memory and erase.
Test sequence
– Disconnect the 2-pin plug from the knock sender -ar-
row-.
– Connect test box -V.A.G 1598/31- to wiring loom of
control unit ⇒ Chapter 24-5. The engine control unit is
not connected here.
– Check wiring between the test box and the 2-pin plug
for interruption according to the Current Flow Dia-
gram.
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-V.A.G 1598/31-
1 106
2 99
Test condition
• Driving
Test sequence
– Connect vehicle system tester -V.A.G 1552-. Start en-
gine and select the address word 01 „Engine electron-
ics“ ⇒ Chapter 01-1.
– Select function 08 „Read measured value block“ and
display group 014.
Reading measured value block 14 ->
– Read off value in display block 4. 840/min 17% 0 activated
Specified value: „activated“.
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– Check the number of combustion misfirings in indica-
tor field 3.
Specified value: 0.
If the specified value is reached:
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